Method and apparatus for casting cementitious blocks



G. ATTERBUHY. METHOD AND APPARATUS FOR CASTING CEMENTITIOUS BLOCKS.

APPLICATION FILED JUNE 3, 1920.

Patented Nov. 1, 1921.

3 SHEETSSHEET 1.

4 TTORNEYS a. ATTERBUHY. METHOD AND APPARATUS FOR CASTING CEMENTITIOUS BLOCKS. APPLICATION FILED JUNE 3| I920- 1,395,662. Patented Nov. 1, 1921.

. 3 SHEETSSHEET 2.

lA/VENTOI? A TTORIVEYS G. ATTERBURY. METHOD AND APPARATUS FOR CASTING CEMENTITIOUS'BLOCKS. APPLICATION FILED JUNE3, 1920. 1,395,662. Patented Nov. 1, 1921.

3 SHEETSSHEET 3.

UNITED STATES PATENT OFFICE.

GROSVENOR ATTERBURY, OF NEW YORK, N. Y.

METHOD AND APPARATUS FOR CASTING CEMENTITIOUS BLOCKS.

Application filed June 3,

T 0 all whom it may concern:

Be it known that I, GnosvENoR ATTERBURY, a citizen of the United States,'and resident of the borough of Manhattan, city, county, and State of New York, have invented certain new and useful Improvements in Methods of and Apparatus for Casting Cementitious Blocks, of which the following is a description.

My invention relates to the art of casting large cementitious blocks and has as one of its objects to provide a method of making large cementitious blocks which will permit the casting of such blocks with increased rapidity.

A second object of my invention is to provide apparatus adapted for use according to my present method and which shall occupy a minimum space for a given capacity, and which can be easily moved from place to place. 7

A third object of my invention i to provide an apparatus of minimum cost for a given output.

11 my prior Patents, Nos. 965,150, 1,241,487, 1,289,599, 1,047,142, 1,207,698 and 1,326,902 I have disclosed a method and apparatus for making large cementitious blocks which have proved of value being used in the production of blocks for certain building constructions. My experience indicates, however, that greater use of large cementitious blocks would follow the introduction of methods and apparatus in accordance with the objects stated above.

The novel features of my invention are pointed out with particularity in the appended claims. The invention itself, however, with further objects and advantages, will best be understood from the following description taken with the accompanying drawings in which Figure 1 is an elevational view partly in section of an apparatus embodying my invention, illustrating the arrangements used; one, two and three mold are used between adjacent cradles Fig. 2 is a section view through the left hand portion of Fig. 1 illustrating the inte rior arrangement and the method of withdrawing the molds from the apparatus.

Fig. 3 is a plan view of the left hand portion of the apparatus of Fig. 1 showing one mold in place and one removed.

Fig. 4 is a sectiontaken on the line 4-fl of Fig. 3, parts being broken away.

Specification of Letters Patent.

Patented Nov. 1, 1921.

1920. Serial No. 386,175.

Fig. 5 is a detail section view taken on the line 55 of Fig. 2, illustrating the construction at one of the lower corners of the mold.

Fig. dig a plan View of an empty mold 1n place in the apparatus.

Fig. 7 is a perspective view of a mold with wedges thereon shown in dotted lines, as the mold appears standing alone.

Fig. 8 is a section view of a modified form of apparatus having cradles with inclined walls on the sides facing the mold.

Fig. 9 is a section view illustrating a third form of apparatus according to my invention.

In the separate views the same parts are indicated by the same reference characters.

In the drawings, 1 have shown latticed cradles, such as 1, standing on the base or foundation, such as 2, which is continuous throughout the length and breadth of the apparatus. The cradles 1 are connected along their ends at the top of frame pieces, such as 3, and along their ends at the bottom by frame pieces, such as 4. Between pairs of cradles I provide space for molds, such as 5. In the form of apparatus shown in Fig. 1, the number of molds accommodated between any tw adjacent cradles is largely immaterial, Fig. 1 illustrating a varying number between different pairs of cradles. According to my invention, the individual molds 5 are relatively long and narrow rectangular structures open at the top and having a closure 6 for supporting the wet cementitious mixture, the member 6 being spaced a material distance from the lower edge of the mold proper whereby the mold is enabled to be set over a form block, such as 7. The molds 5 are conveniently made according to my previous Patent No. 1,326,902, in which the individual molds are not made sufficiently strong to retain their exact shape when first filled and must be supported at the sides to withstand the hydrostatic pressure of the wet mixture. Along the sides of each mold are sets of wedge-shaped members, such as 8, which are preferably secured rigidly to the sides of the mold so as to be lifted and transported therewith. The wedges 8 are placed sufliciently close together so that when the wedges are properly supported, the mold walls will be sustained so as to produce plane surfaces along the longitudinal sides of the cast blocks. The side of a given mold adj acent a cradle, such as 1, has the wedges 8 casting a block.

resting against the complementally inclined surfaces of vertically placed strips, such as 9. The supporting members 9 are supported in turn by the cradles 1, resting firmly against them. In the form of apparatus shown in Fig. l, the sides of the cradles are vertical and the' strips 9 are consequently of wedge shape. The faces of the members 9 on the side toward the molds are preferably provided with cementitious layers, such as 10,- which insure an exact. fit between the contacting surfaces and which also prevent undue wear and are readily renewable. The layers 10 are preferably of gypsum or other cementitious material or mixtures of materials which expand slightly upon setting. By using such material 'I insure a closefit between the layers 10 and the wedge members 8. It will be seen that the lower edges of the molds 5 rest on the base or'foundation 2 when in place in the apparatus and if more than one mold is used between a given pair of cradles means must be provided for supporting the adjacent faces of the molds. I arrange for this by the use of pairs of rectangular members, such as 11, which extend across the frame from one side member 8 to the other, and which have wedge-shaped projections, such as 12, arranged tosupport the wedges 8 on the adjacent molds. The faces of the wedge portions 12 may also carry cementitious layers 10 as in the case of the supporting members 9. The members 11 are supported at the top by screws, such as 13, working in brackets 14 fixed to the upper side bars 3. By this means the members 11 can beadjusted vertically so as to fit and bear evenly against the jacket and also if necessary to avoid any tendency to jam as the jacketis removed from the cradle. For lifting the molds or jackets from the apparatus, I prefer to use eye-bolts, such as 15, which are secured into the upper edges of the molds and which may be-conveniently attached to hoisting apparatus.

In the form shown in Fig. 8, I have shown a'pairof cradles, such as 1, with a single mold space between them, the cradles in this case being contracted at the top and presenting inclined faces toward the mold space.

In this case the supporting strips 9 fixed to the cradles are not wedge-shaped, the inclination of the cradles being the same as that of the wedges 8. I may use either form of cradle l or 1, as circumstances indicate to be desirable. In the act of casting cementit ous slabs according to my present invention, the molds may be readily lifted in and out of the frame and the molds are the only parts of the apparatus which it is ordinarily necessary to move throughout the cycle of In other words, the side supports of the mold jackets 5 are fixed throughout the operation,'although the intermediate members 11 and also the wedges may, of course, be adjusted from time to time, if it seems necessary. After the block has set, the jacket containing the same is hoisted out of the casting apparatus and run by an overhead crane or other means to a hardening or curing room and another jacket substituted between the cores for a second casting, while the preceding one is hardening sufficiently to permit opening, cleaning and oiling of the jacket or mold 5, ready for replacement in the cradle. As many jackets or molds can be used for each mold space or pair of cradles as the speed of setting and hardening permits. Assuming, for example,

that the second set of the cement mixture occurs threehours after casting, depending on heat conditions, the first jacket and cast would occupy the cradle four hours. In other words, six casts can be made in a given mold space in a twenty-four hour day. When operating according to the prior practice, however, the castingis not normally hard enough to be lifted out .of the. mold in much less than twenty-four hours unless an accelerating substance is used.

It will be seen also that in case cores are used to form blocks of tubular section, the same motion which lifts the 'mold from the cradle also strips the block from the core such as 20. This does away with-the necessity of any gearing for drawing down the cores previous to the removal of'the casting as the material is not hard. enough to grip the core. I

In the arrangement illustrated in Fig.9, the space for receiving the molds isexcavated in the earth, thus doing away with the necessity for a framework or cradles. In this arrangement, the surfaces of the excavation are preferably coveredv by a layer16 of cementitious material, the'free surface of which is given such a slope that the wedges 8 may fit closely against it, so as to support the sides of the mold. Theexcavation may be of suihcient size to accommodateany desired number of molds simultaneously.

In all three-forms of apparatusillustrated herein,'when conditions require it, the ends of the molds may be supported by wedges in the same manner as illustrated in. case of the sides of the molds. The ends of the molds may be separate from the sides, if desired. 1

It will be seen that if more than one mold or jacket 5"is used in a given mold space, I may advantageously use the method of balancing the .hydrostatic'pressure of the wet cement in the adjacent molds as isdis-. closed in my prior Patent No. 1,326,902.

It will also be seen that the trussed cradles are of simple but strong mechanical construction and are moreover set in a substantial frame whereby they are supported at the ends both top and bottom. I find by paratus is reduced substantially as compared to apparatus using movable steel or reinforced sides. Furthermore, according to the present arrangement, a trussed cradle may form the end support of two different mold spaces, thus reducing the number as well as the weight of these supporting sides in a battery of molds by nearly one-half. This, of course, would be impossible if the method of operation required that the side walls of the mold supports be movable. If conditions are such as to favor excavation, the weight of the apparatus may be reduced still further.

It will be seen moreover that the floor space occupied by the apparatus according to my present invention depends merely upon the actual thickness of the section .to be cast and is not influenced by the necessity for having to provide space to accommodate the apparatus when opened.

It will also be seen that my present apparatus is very strong in proportion to its weight and may be very economically constructed.

While I have illustrated and described in detail a particular arrangement for producing a wedging action against the mold automatically as it is lowered into position to receive material to be cast, I do not limit myself to this form of apparatus, but claim as my invention all forms of apparatus whereby this result is obtained.

Having thus described my invention, 1 claim:

1. The method of making large blocks of cementitious material in molds having vertical sides of so light construction as to require support against the hydrostatic pressure when first filled comprising supporting the sides of the mold only until the cast material sets sufficiently to first relieve the hydrostatic pressure, then withdrawing the mold and casting from the support and retaining the casting in the mold for further hardening and curing.

2. The method of making large hollow blocks of cementitious materials in molds having vertical sides of so light construction as to require support against the hydrostatic pressure when first filled and having cores therein comprising supporting the sides of the mold only until the cast material sets sufficiently to relieve the hydrostatic pressure, withdrawing the mold from the support and stripping the casting from the cores while still soft, and retaining the casting in the mold until sufficiently hard to permit the opening of the mold.

3. An apparatus for casting cementitious blocks comprising in combination fixed side walls for sustaining the hydrostatic pressure of the material as cast, a mold for cooperating with said walls having sides and a weight supporting bottom piece and adapted to be inserted and removed from between said walls, and means whereby said mold is automatically brought into such position that its sides are closely supported from said walls upon being placed in position between said walls for receiving material to be cast.

4. An apparatus for casting cementitious blocks comprising, in combination, fixed side walls for sustaining the hydrostatic pressure of the material, a mold for cooperating with side walls having sides and a weight supporting bottom piece and adapted to be inserted and removed from between said walls, and means whereby a wedging action is produced automatically between said walls and the sides of said mold as the mold is placed between said wall in position to receive material to be cast.

5. An apparatus for casting large cementitious blocks comprising in combination fixed supporting means for sustaining the pressure of the wet material, members connecting said supports, said supports having inclined parts narrowing the mold space at the bottom and cementitious material on said inclined sides.

6. A casting apparatus for cementitious material having a mold space of sufiicient volume to permit casting simultaneously in a plurality of individual molds or ackets, molds for said space, and wedge-like members intermediate adjacent molds.

7. The method of making blocks of cementitious material in molds having vertical sides of so light construction as to require support against the hydrostatic pressure when first filled comprising supporting the sides of the mold only until the cast material is set sufficiently to relieve the hydrostatic pressure to the extent that such pressure may be sustained by the light mold without distortion, withdrawing the mold from the support as soon as the material is suiiiciently set to retain the shape of the mold with only the sustaining action of the mold, and retaining the casting in the mold until sufiiciently hard to permit its removal therefrom.

GROSVENOR ATTERBURY. 

